Upholstered seating



Nov. 20, 1962 c. A. BRbwN 3,064,281

UPI-IOLSTERED SEATING 2 Sheets-Sheet I Filed Sept. 16, 1960 Nov. 20, 1962 c. A. BROWN UPHOLSTERED SEATING 2 Sheets-Sheet 2 Filed Sept. 16, 1960 FIG.

FIG. 6

INVENTOR. CLYDE A. BROWN @MW United States Patent Ofifice Bfihdfifil Patented Nov. 20, 1962 3,864,281 UPHOISTERED SEATING Ciyde A. Brown, Lakewood, Cold, assignor, by mesne assignments, to Hallacir & Howard Manufacturing Co., a division of Boise-Cascade Corporation, a corporation of Delaware Filed Sept. 16, 1960, Ser. No. 56,443 1 Claim. (Cl. -3535) The present invention relates to the field of personnel seating and, more particularly, to upholstered seating for bench type installations, such as in church pews, court rooms and the like.

Previously, many different types of seating have been designed and provided, and in more recent years the advantages of providing upholstering or cushioning for benches and pews has been recognized.

An object of this invention is to provide a simplified and economical system that will make upholstered seating available for new and remodelled public seating installations.

Another object of this invention is to provide means for the efficient utilization of inherently economical structural shapes and elements.

A further object of this invention is to provide a novel spring support frame or seat cushion which cooperatively uses conventional structural support members in a seating system together with conventional types of spring elements that may be easily placed and attached to the frame in accordance with principles of the invention.

A further object of this invention is to provide a cushion frame made of metal elements of full strength design and to provide for use therewith a wooden locking member that holds spring elements in place on said frame and also provides an upholstering tacking strip.

Further objects and advantages of the present invention will be apparent from the appended description and drawings, in which:

FIG. 1 is a perspective view in partial cut-away section illustrating features of this invention,

FIG. 2 is a cross-sectional elevation taken through the cushion shown in FIG. 1 and further illustrating features of the invention,

FIG. 3 is a plan view showing further structural features of an embodiment of the invention,

FIGS. 4 through 9 are, respectively, plan views and side elevations illustrating successive steps used to obtain a desired hook end for a type of spring used in connection with this invention, with FIG. 9 further showing the insertion of the derived spring element into a frame structure, and

FIG. 10 is a side elevation comparable to that of FIG. 9 showing the spring element in its stretched and tackstrip locking position of usage.

Briefly stated, the present invention provides means for the construction of an economical and efiicient seat cushion element in which the strength of steel frame members is cooperatively utilized with Wooden lock strip tacking members to provide a structurally strong but economical seat cushion frame that may be easily upholstered. In addition to providing a convenient upholstering tacking strip, the wood element serves to reinforce and stiffen the main steel frame members and likewise serves to interlock the necessary spring elements and steel frame.

The specific features of separate embodiments of the invention may be more particularly described in connection with the appended drawings. In these drawings FIGS. 1, 2 and 3 show a first embodiment of the invention, with FIG. 1 being a general illustration of the manner of use of the invention. In this figure it will be seen that a church pew type of bench seating 11 is conemplated. As in conventional construction, the bench seat 11 includes the pew end supports 12 to which a seat back 13 and a seat 14 are attached as necessary to provide seating for several people. In keeping with recent trends this bench seat, as illustrated, is upholstered so that the back 13 and seat 1 will be cushioned to provide more comfortable seating for the occupants. Such cushioned seating is presently in considerable demand for new bench type seating installations, and also it has been found that many seating installations are being remodelled to provide for the greater comfort of the users.

In remodelled or even new installations the main emphasis seems to be in the provision of seat cushions, and accordingly many installations are made or remodelled in which the back 13 is left unupholstered. The present invention likewise is mainly concerned with the provision of novel seat cushioning means and with the method and apparatus for obtaining improved comfort at an economical cost.

The general features of one embodiment that is typical of the invention is shown in FIGS. 2 and 3. Here the seat 14 is seen to have a metal frame 16 made up of longitudinal segments 15 and end cross members 17. Since it is true that intermediate supports for bench type seating are costly, it is necessary that economical systems have relatively longer spans between the end supports 12 or between end supports 12 and any intermediate supports. The present inventor has found that a frame 16 made of metal elements can best provide the desired economy of construction. Further, it has been found that a type of steel channel member often used in building construction is particularly well adapted for use in cushion frames. Accordingly, it should be noted that the frame 16 is made up of cut sections of Unistrut channel sections. These elements are joined each to each, as by welding 18, at the corners to provide a rigid frame 16 for the seat 14.

As shown in FIG. 2, the structure of a Unistrut channel member includes an outwardly disposed back element 19, two channel flanges 21 and 22 which may be provided with a reinforcing ridge 23 running longitudinally therealong, and paired return elements 2 and 26 which close off a portion of the channel opening and, in fact, provide a near box-like cross-sectional configuration. The cross-section is, as stated, of a type conventionally used in building construction, and it is recognized as having a relatively high structural strength per unit of Weight. For these reasons, the Unistrut channel member is in itself ideally suited for use as the longitudinal segments 15 and cross frame members 17 of a seat cushion frame 16.

A main deterrent to its use for upholstered type seating has undoubtedly been the fact that it would be difficult to attach upholstering fabrics or covers to such a metal frame. In accordance with the present invention, this shortcoming has been avoided by the provision of a wooden nailing or tacking strip 27 which is adapted to be inserted into the interior of the Unistrut channel so th-at'itsinner-faee 2 will bemaint-ained in-a-position-of alignment with the faces of the return elements 24 and 26. Preferably, the nailing strip 27 is of a size, shape and configuration such that it may be inserted into the enclosure within the channel section formed by the return elements 24 and 26, and it has been found that if the nailing strip is of the proper size and shape, it will be firmly held in position by the resilience of the channel flanges 21 and 22. At the same time it has been observed that. insertion of such nailing strip 27 into the metal channel piece, tends to stifien such metal channel and to give itimprovedweight supporting characteristics.

The combined use of these metal and wooden elements provides a cushion frame 16 that is well suited-to bench typeseating installations. The frame-16 has adequate strength and rigidity sothat it may be joineddirectly to the upright end supports 12 as by the use of lag screws 29o: othersimilar fastening elements to provide a cushion frame which actually may be extended in cantilever fashion a considerable distance forwardly past the upright end support.

In addition tothe provision of a strong-and serviceable, support cushion frame, this invention provides novel means for attaching conventional types of spring elements to such frame. In FIGS. 2 and .3 a type of flex steel,

no-sag. spring element 31 is illustrated. Thistype of spring element is well known in the upholstering art and is used in many different types of cushion installations. Usually this type of spring is joined to a wooden frame through use of a clip element tightened about an end loop of the spring and nailed directly to the wooden frame. Inthe present embodiment of the invention it should be noted that the loopend 32 ofvthe no-sag spring element 31 is merely hooked through an opening 33 punched in the top of the Unistrut channel frame 16 so that a hook 34-011 such loop end 32 will extend downwardly into the interior of the, box-like channel section and will usually engage the wooden tacking strip 27.

In order touse this economical fastening system, it

will be obvious that the loop end 32 of the spring element 31 must be bent downwardly with respect to tangent planes definedby the, general spring element surface. As illustrated,- the hooks 34 of spring elements 31 may etually be driven into. the wood tacking strip 27 to ecurely hold such ends 'in place. This arrangement substantially eliminates wy noise that might be derived from the scraping togetherof parts and elements.

Likewise illustrated in FIGS, 2 and 3'are other features of the cushion structure which are worthy of note. In order to provide an adequate spring system, it is intended that the flex steel spring elements 31 Will be affixed to theframe 16 at spaced positions along the length thereof, and various types of tie elements, such as the hook ties 36 and the end coil springs 37, will beused to develop the cooperative strength of the separate spring elements 31.

Likewise, it should be noted that a typeof cushion padding. 38 will be used which includes a plurality of longitudinal reinforcingwires 39, which tend to distribute any seatingload over a considerable number of spring elements 31. The cushion padding38, as illustrated, is a unit'filled with materials, such as hair, eXcelsior or the like, all enclosed Within a fabric or burlap cover 41 so that the pad may be conformed to the arc-like shape of the spring elements 31. .Further padding :42 is provided along the front edge of the seat cushion frame 16 either by an extension of the padding 38'or by separate padding so that the outer face 19 of the channel section *and the corners thereof will be protected to prevent excessive wear of the padding or of the cushion cover 44. The cover itself completely encloses all padding elements and is drawn tight over the springs 31 and over the padding 38 so that the edges '46 of the cover 44 may be brought over and around the seat frame 16 and into contact with the exposed face 28 of the wooden strip 27. When in Cit this desired position, staples 47, upholstering tacks or the like; maybe-used to seeure-tl1e-cover 46--to -the-nailing and tacking strip 27 to complete a seat cushion 14. The provision of a wooden nailing strip for the tacking of the upholstery cover 46 together with a steel structural member makes it possible to provide an upholstered seat 14 that is easy to manufacture and that is of low cost.

The successive steps that may be followed in order to provide the hooks 34 on the end loops 32 of the spring elements 31 are shown in FIGURES 4 through 9. In FIGURES 4 and 5 it is shown that one of the end loops 32 is cut in the position illustrated to provide a terminal radius and end 48. After both ends'of a desired length of spring element 31 have been severed from a coiled supply, the terminal end is bent to positions at right angles with the general plane of the remaining spring elements 31. This positions the terminal end 48 in a downwardly extending attitude with respect to the general spring element 31, as illustratedin FIGURES 6 and 7. A final step, as illustrated in FIGURES 8 and 9, requires that the terminalend 48 and a portion of the end loop 32 be bent outwardly at right angles. This final bend will dispose the hooks34 in a position disposed centrally of, the lateral extentof the convolutions 49 forming the FIG.- 9 illustrates the initial introduction of a book 34 through the punched opening 33 in the Uni-Strut steel frame member 16. In this figure the spring element 31. is shown in its approximate unstretched arched curvature. When in this attitude the hooks 34 will be against the upper return element 24, and the nailing strip 27 may be loosely engaged within the interior of the metal channel member. When the spring element 31 is stretched between the opposed longitudinal frame members 15 and when the hooks 34 are inserted through the respective openings 33 on such longitudinal frame members 15, the curvature of the spring element 31 will be flattened. The hooks 34 which tend to stay in a position normal to the curve will be moved backwardly. as seen in FIGURE 10 to engage the nailing strip 27 in such manner as to hold the nailing strip 27' in position tight against the back '34. will ordinarily :be brought into engagement with the nailing strip 27. The total force exerted against the nailing strip 27 will -be more than adequate to maintain such strip in the desired position so that staples 47- may be driven to hold the seat cover 46 securely in position. Since with this arrangement the hooks 34- and terminal ends 48act against the wooden nailing strip 27, most metal to metal contact between the spring and frame is avoided. Accordingly, seat cushions made in keeping with this invention avoid annoying spring noises.

Whilethe type-of'hook ends shown in the FIGURES '4 through 10 are preferred, it is obvious that a straightend hook'as illustratedin FIGURE 2 may be used. When other types of hook ends are of a cooperative design such that they will engage a nailing strip 27 and tend to hold the nailing strip in position, thebenefits. of this invention will be possible. This desirable purpose and other advantages of'this invention maynecessarily be accomplished through the use of alternate forms and arrangements' of-parts and elements. All such modifications and changes as come within the scope of the hereunto appended claim'are considered tobe a part of this in:

flanges and return elements on said flanges providing a box-like structure, said upper flange providing spaced openings therein, tacking strips of material adapted to receive and hold fastening elements disposed within said channel members and between the return elements on said flanges, cushion supporting spring elements engaged between the openings on opposed channel piece flanges to provide resilient support for said cushion, and hook ends on said spring elements extending downwardly through said upper flange openings to engage the tacking strips within said opposed channel pieces for holding said strips in desired position at the inwardly disposed face of said channel whereby said tacking strip may be used to facilitate the placement and retention of an upholstered cover for said seat cushion and the noise of spring action against said channel pieces is minimized.

References Cited in the file of this patent UNITED STATES PATENTS 1,665,351 Gibbs Apr. 10, 1928 1,677,500 Stiles July 17, 1928 2,218,708 Haberstump Oct. 22, 1940 FOREIGN PATENTS 623,414 Great Britain May 17, 1949 868,783 Germany Feb. 26, 1953 

